U.S. patent application number 10/921207 was filed with the patent office on 2006-02-23 for functionalized poly (ethylene-co-syndiotactic propylene).
This patent application is currently assigned to CORNELL RESEARCH FOUNDATION, INC.. Invention is credited to Geoffrey W. Coates, Lewis J. Fetters.
Application Number | 20060041070 10/921207 |
Document ID | / |
Family ID | 35910500 |
Filed Date | 2006-02-23 |
United States Patent
Application |
20060041070 |
Kind Code |
A1 |
Fetters; Lewis J. ; et
al. |
February 23, 2006 |
FUNCTIONALIZED POLY (ETHYLENE-CO-SYNDIOTACTIC PROPYLENE)
Abstract
Poly(ethylene-co-syndiotactic propylene) functionalized with
group(s), that enable crosslinking, e.g., vinyl or anhydride
group(s), in admixture with crosslinking agent and filler is
subjected to crosslinking reaction to provide filled copolymer. The
presence of propylene in syndiotactic sequences provides lower
entanglement molecular weight compared to other propylene placement
and therefore allows more filler to be present than for other
propylene placement. Crosslinking provides filled materials with
good elastomeric properties.
Inventors: |
Fetters; Lewis J.; (Ithaca,
NY) ; Coates; Geoffrey W.; (Ithaca, NY) |
Correspondence
Address: |
BACON & THOMAS, PLLC
625 SLATERS LANE
FOURTH FLOOR
ALEXANDRIA
VA
22314
US
|
Assignee: |
CORNELL RESEARCH FOUNDATION,
INC.
Ithaca
NY
|
Family ID: |
35910500 |
Appl. No.: |
10/921207 |
Filed: |
August 19, 2004 |
Current U.S.
Class: |
525/232 ;
525/240; 525/242 |
Current CPC
Class: |
C08F 2500/03 20130101;
C08F 2500/16 20130101; C08F 210/06 20130101; C08F 236/20 20130101;
C08F 210/18 20130101; C08F 210/18 20130101 |
Class at
Publication: |
525/232 ;
525/240; 525/242 |
International
Class: |
C08L 9/00 20060101
C08L009/00; C08L 23/04 20060101 C08L023/04 |
Claims
1. Poly(ethylene-co-syndiotactic propylene) functionalized with
group(s) that enable crosslinking, the functionalized
poly(ethylene-co-syndiotactic propylene) comprising from 49-70 mole
percent ethylene, from 50-25 mole percent propylene, and from 1-5
mole percent crosslinking functionalizer, from 50 to 100 mole
percent of the propylene being present in syndiotactic sequences,
the functionalized poly(ethylene-co-syndiotactic propylene) having
M.sub.n ranging from 1,000 to 2,000,000 and M.sub.w/M.sub.n ranging
from 1 to 10, the group(s) that enable crosslinking being vinyl
group(s).
2. The functionalized poly(ethylene-co-syndiotactic propylene) of
claim 1, which comprises from 54-65 mole percent ethylene, from
45-32 mole percent propylene, and from 1-3 mole percent
crosslinking functionalizer, and has M.sub.n ranging from 400,000
to 750,000 and M.sub.w/M.sub.n ranging from 1.10 to 1.30.
3. (canceled)
4. The functionalized poly(ethylene-co-syndiotactic propylene) of
claim 2 where the crosslinking functionalizer is selected from the
group consisting of C.sub.5-C.sub.10-.alpha.,.omega.-dienes.
5. The functionalized poly(ethylene-co-syndiotactic propylene) of
claim 4 where the crosslinking functionalizer is 1,5-hexadiene.
6.-9. (canceled)
10. The functionalized poly(ethylene-co-syndiotactic propylene) of
claim 4 in admixture with from 0.01 to 10 weight percent
crosslinking agent and from 5 to 50 weight percent filler.
11. The admixture of claim 10 which is subjected to crosslinking
reaction.
12. The functionalized poly(ethylene-co-syndiotactic propylene) of
claim 5 in admixture with from 0.01 to 10 weight percent
crosslinking agent and from 5 to 50 weight percent filler.
13. The admixture of claim 12 which is subjected to crosslinking
reaction.
14.-17. (canceled)
18. The functionalized poly(ethylene-co-syndiotactic propylene) of
claim 4 where ethylene, propylene and the 1,5-hexadiene monomers
are used to produce the functionalized
poly(ethylene-co-syndiotactic propylene).
19. The admixture of claim 10 where the crosslinking agent is
sulfur.
20. The admixture of claim 19 which is subjected to crosslinking
reaction.
21. The admixture of claim 12 where the crosslinking agent is
sulfur.
22. The admixture of claim 21 which is subjected to crosslinking
reaction.
Description
TECHNICAL FIELD
[0001] This invention is directed to random ethylene propylene
copolymers.
BACKGROUND OF THE INVENTION
[0002] Hustad, P. D., Tian, J. and Coates, G. W., J. Am. Chem. Soc.
124, 3614-3621 (2002) discloses ethylene propylene copolymerization
using a living catalyst system of bis(phenoxyimine)-based titanium
catalyst activated by methylaluminoxane. The copolymer that was
produced contained propylene present in syndiotactic sequences, but
the article does not mention this and there was no recognition of
this at the time of the synthesis set forth in the article or at
the time of publication and there was no recognition or disclosure
that the copolymer could accommodate more filler than if propylene
were present in atactic or isotactic sequences.
[0003] Coates et al U.S. Pat. No. 6,562,930 discloses block
copolymers containing syndiotactic block(s) and ethylene propylene
blocks made using catalyst system of bis(salicylaldminato)titanium
complex activated by methylaluminoxane. The ethylene propylene
blocks contained propylene present in syndiotactic sequences, but
the patent does not disclose this.
SUMMARY OF THE INVENTION
[0004] It has been discovered herein that the copolymers of
ethylene and propylene made using a catalyst system of
bis(salicyladiminato)titanium complex activated by
methylaluminoxane contain propylene present in syndiotactic
sequences and that this presence provides markedly higher plateau
modulus and therefore significantly lower entanglement molecular
weight compared to atactic and isotactic counterparts and that
these characteristics are retained or increased when the copolymers
are functionalized to enable crosslinking and that these
characteristics allow more filler to be present in crosslinkable
admixtures and after crosslinking is carried out to obtain
elastomers than in the case of isotactic and atactic
counterparts.
[0005] In one embodiment of the invention herein, there is provided
poly(ethylene-co-syndiotactic propylene) functionalized with groups
that enable crosslinking, the functionalized
poly(ethylene-co-syndiotactic propylene) comprising from 49-70 mole
percent ethylene, from 50-25 mole percent propylene and from 1-5
mole percent crosslinking functionalizer, from 50 to 100 mole
percent of the propylene being present in syndiotactic sequences
(i.e., with consecutive propylenes being in syndiotactic
relationship), the functionalized poly(ethylene-co-syndiotactic
propylene) having M.sub.n ranging from 1,000 to 2,000,000 and
M.sub.w/M.sub.n ranging from 1-10.
[0006] The functionalized poly(ethylene-so-syndiotactic propylene)
is advantageously used in admixture with from 0.01 to 10 weight
percent crosslinking agent and from 5 to 50 weight percent filler
including a weight percent filler greater than that tolerated when
atactic or isotactic counterparts are present.
[0007] The admixture is crosslinked to provide filled
elastomer.
[0008] The molecular weights (M.sub.n and M.sub.w) and
polydispersities (M.sub.w/M.sub.n) are measured by gel permeation
chromatography using polystyrene standards.
[0009] The term "elastomer" is used herein to mean a thermosetting
high polymer having the ability to be stretched to at least twice
its original length and to retract very rapidly to approximately
its original length when released.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a graph of loss modulus G''(.omega.) versus
angular frequency .omega. in sec.sup.-1 for composition 1-6a.
[0011] FIG. 2 is a graph of loss modulus G''(.omega.) versus
angular frequency .omega. in sec.sup.-1 for composition 2-227a.
[0012] FIG. 3 is a graph of loss modulus G''(.omega.) versus
angular frequency .omega. in sec.sup.-1 for composition 2-12.
[0013] All the figures relate to Background Example 4.
DETAILED DESCRIPTION
[0014] The functionalized poly(ethylene-co-syndiotactic propylene)
preferably comprises from 54-65 mole percent ethylene, from 45-32
mole percent propylene, and from 1-3 mole percent crosslinking
functionalizer, and has M.sub.n ranging from 400,000 to 750,000 and
M.sub.w/M.sub.n ranging from 1.1 to 5, e.g., 1.10-1.30.
[0015] The most important functionalized
poly(ethylene-co-propylene) comprises 60 mole percent ethylene, 38
mole percent propylene and 2 mole percent crosslinking
functionalizer.
[0016] The groups enabling crosslinking include, for example, vinyl
group(s) and anhydride group(s).
[0017] For providing vinyl group(s) for enabling crosslinking, the
crosslinking functionalizer is selected from the group consisting
of C.sub.5-C.sub.10.alpha.,.omega.-dienes, e.g., 1,5-
hexadiene.
[0018] For providing anhydride groups for enabling crosslinking,
the crosslinking functionalizer can be, for example, maleic
anhydride
[0019] We turn now to synthesis of the functionalized
poly(ethylene-co-syndiotactic propylene) where the group(s)
enabling crosslinking are vinyl group(s). A pressure reaction
vessel is charged with compound that converts titanium of the
catalyst to cationic form to activate it, e.g., methylaluminoxane
(MAO), very preferably polymethylaluminoxane (PMAO), used in an
amount ranging from 10:1 to 1,000:1 on a [Al]/[Ti] basis and with
aprotic solvent, e.g., toluene. Propylene is then added, then
ethylene, then .alpha., .omega. diene, e.g., 1,5-hexadiene. Then
catalyst dissolved in aprotic solvent is added. The catalyst is a
catalyst providing living polymerization and chain end control by a
mechanism which is exclusively secondary 2,1 insertion mechanism
and is preferably a bis(salicyladiminato) titanium complex where
optionally substituted phenyl or cyclohexyl on nitrogen catalyzes
syndiospecific polymerization of propylene and has formula III in
U.S. Pat. No. 6,562,930 and is, for example, Catalyst F or G, very
preferably Catalyst G of U.S. Pat. No. 6,562,930. Reaction
temperature can range, for example, from -20 to 100.degree. C. and
is preferably 0.degree. C., and reaction times can range, e.g.,
from 1 hour to 50 hours.
[0020] We turn now to synthesis of the functionalized
poly(ethylene-co-syndiotactic propylene) where the group(s)
enabling crosslinking are anhydride group(s). The synthesis of
copolymer is carried out as described in the above paragraph except
that the diene is omitted. The polymer is mixed with the anhydride,
e.g., maleic anhydride, in the presence of a radical initiator,
e.g., benzoyl peroxide or di-tert-butyl peroxide or
azobisisobutyronitrile, present in an amount of 0.1 to 5 weight
percent. It is believed the radical homolyzes a C--H bond, creating
a C-based radical on the main chain which reacts with the maleic
anhydride to randomly add anhydride groups along the polymeric
backbone. Heating at a temperature ranging from 100 to 300.degree.
C. for a time period ranging from 10 minutes to 5 hours provides
the functionalized copolymer.
[0021] For use, the functionalized copolymer, crosslinking agent
and filler are formed into a desired object which is subjected to
heat to crosslink the copolymer and fix the shape of the object.
Without crosslinking, the composition would be subject to cold flow
over time. Network formation via crosslinking is a necessity for
practical application for the filled composition.
[0022] Where the group enabling crosslinking is vinyl group, the
crosslinking agent is preferably sulfur admixed in an amount
ranging from 0.1 to 5 weight percent and heating, e.g., for a time
period ranging from 10 minutes to 5 hours effects the crosslinking
reaction.
[0023] Where the group enabling crosslinking is anhydride group,
the crosslinking agent is a dinucleophilie, e.g., a dialcohol,
e.g., 1,6-hexanediol or ethylene glycol or a diamine, e.g.,
hydrazine, methlenediamine, ethylenediamine, termethylenediamine,
or hexamethylene diamine. The crosslinking agent is admixed in an
amount ranging from 0.1 to 5 weight percent and crosslinking is
effected by ester or amide crosslink formation.
[0024] The filler can be, for example, mineral oil, silica, carbon
black, graphite, etc.
[0025] Too much filler in the crosslinked composition leads to
diminished tensile strengths.
[0026] Filled, molded and crosslinked materials from
poly(ethylene-co-syndiotactic propylene) can be used in a wide
range of elastomer application where polydienes and conventional
poly(ethylene-co-propylene) are now used.
[0027] One important application is for vehicle tires. The
characteristic of no internal double bonds, i.e., within the chain,
provides long term chain stability. The low glass transition
temperature is a plus since its value of about 215.degree. C. is
only several degrees larger than that of polyisoprene.
[0028] The invention and background and benefits thereof are
exemplified in the following background and working examples.
BACKGROUND EXAMPLE 1
Synthesis of 1-6a
[0029] Sample 1-6a of poly(ethylene-co-syndiotactic propylene) was
prepared as follows:
[0030] A 6 oz. Lab-Crest.RTM. glass pressure reaction vessel
(Andrews Glass) was charged with PMAO (0.30 g. [Al]/[Ti]=250) and
toluene (50 mL). The reactor was placed in an ice-bath. The
nitrogen atmosphere in the reaction was exchanged with propylene
three times. Propylene was condensed into the reactor for 30 min at
30 psi. The ethylene was reacted at 31 psi. The catalyst solution
(19 mg of Catalyst G described in U.S. Pat. No. 6,562,930, in 5 mL
toluene) was injected by syringe. After 90 min, acidic methanol (1
mL) was added by syringe to quench the polymerization. The reactor
was vented and the polymer precipitated in acidic methanol (400
mL). After stirring for several hours, the polymer was filtered,
washed with methanol and dried (2.27 g, M.sub.n=482,000 g/mol;
M.sub.w/M.sub.n=1.18).
BACKGROUND EXAMPLE 2
Synthesis of 2-227a
[0031] Sample 2-227a of poly(ethylene-co-syndiotactic propylene)
was prepared as follows:
[0032] A 6 oz. Lab-Crest glass pressure reaction vessel was charged
with PMAO (0.30 g, [Al]/[Ti]=500) and toluene (100 mL). The reactor
was placed in an ice-bath. The nitrogen atmosphere in the reaction
was exchanged with propylene three times. Propylene was condensed
into the reactor for 30 min at 30 psi. Ethylene was added at 40
psi. The catalyst solution (9 mg of Catalyst G described in U.S.
Pat. No. 6,562,930, in 5 mL toluene) was injected by syringe. After
60 min, acidic methanol (1 mL) was added by syringe to quench the
polymerization. The reactor was vented and the polymer precipitated
in acidic methanol (400 mL). After stirring for several hours, the
polymer was filtered, washed with methanol and dried (3.05 g,
M.sub.n=528,000 g/mol; M.sub.w/M.sub.n=1.18).
BACKGROUND EXAMPLE 3
Synthesis of 2-12
[0033] Sample 2-12 of poly(ethylene-co-syndiotactic propylene) was
prepared as follows:
[0034] A 6 oz. Lab-Crest( glass pressure reaction vessel (Andrews
Glass) was charged with PMAO (0.19 g, [Al]/[Ti]=500) and toluene
(300 mL). The reactor was placed in an ice-bath. The nitrogen
atmosphere in the reaction was exchanged with propylene three
times. Propylene was condensed into the reactor for 30 min at 20
psi. The ethylene tank was attached at 20 psi. The catalyst
solution (19 mg of Catalyst G described in U.S. Pat. No. 6,562,930,
in 5 mL toluene) was injected by syringe. After 60 min, acidic
methanol (1 mL) was added by syringe to quench the polymerization.
The reactor was vented and the polymer precipitated in acidic
methanol (400 mL). After stirring for several hours, the polymer
was filtered, washed with methanol and dried (1.8 g,
M.sub.n=537,000 g/mol; M.sub.w/M.sub.n=1.27).
BACKGROUND EXAMPLE 4
Comparison of Rheological Properties
[0035] Loss modulus G'' data was collected for samples 1-6a, 2-227a
and 2-12 over a frequency (.omega.) range of 10.sup.-3 to 10 rads
sec.sup.-1, using a Rheometrics ARES rheometer in an oscillatory
shear mode with 8 mm or 10 mm diameter parallel-plate geometry. RSI
Orchestrator software was used to automatically derive master
curves at a reference temperature (T.sub.0) of 348.degree. K by a
two dimensional minimization technique. Results for 1-6a are shown
in FIG. 1. Results for 2-227a are shown in FIG. 2. Results for 2-12
are shown in FIG. 3.
[0036] The plateau modulus G.degree..sub.N in each case was
calculated from the loss modulus data according to the formula: G N
o = ( 2 .pi. ) .times. .times. .intg. - .infin. .infin. .times. G *
.function. ( .omega. ) .times. .times. d ln .function. ( .omega. )
##EQU1## where the units were in MPA in accordance with the
procedure of Colby, R. H., Macromolecules 24, 3873 (1991).
[0037] The entanglement molecular weight M.sub.e was calculated
from plateau modulus data according to the following formula: M e =
.rho. .times. .times. RT G N o ##EQU2## where .notgreaterthan. is
polymer density (0.827 g/cm.sup.3 at 348K), R the gas constant
(8.314 J mol.sup.lK.sup.l) and T the reference temperature
(348K).
[0038] Molecular characteristics for the copolymers are shown in
Table 1 below: TABLE-US-00001 TABLE 1 T.sub.g M.sub.n M.sub.w Mole
Fraction COPOLYMER (K) kg/mol kg/mol Ethylene 1-6a 215 482 569 0.57
2-227a 214 528 641 0.63 2-12 214 537 680 0.67
[0039] Plateau modules G.degree..sub.N data and entanglement
molecular weight M.sub.e for the three copolymer samples at
T.sub.0=348K determined as described above is set forth in Table 2
below. TABLE-US-00002 TABLE 2 COPOLYMER G.degree..sub.N (MPa)
M.sub.e (g/mol.sup.-1 1-6a 2.07 1160 2-227a 1.70 1400 2-12 1.85
1300
[0040] Conversion of the Table 2 M.sub.e data to 298K and
comparison to other samples at 298K is set forth in Table 3 below.
TABLE-US-00003 TABLE 3 M.sub.e Sample g mol.sup.-1 PE 600 1.6a 920
2-12 1020 2-227a 1140 s-PP 1560 PEP 1690 a-PP 4400
In Table 3, PE means polyethylene, s-PP means syndiotactic
polypropylene having [rrrr] pentad content of 0.96, PEP means
random copolymer of ethylene and propylene without propylene in
syndiotactic sequences and a-PP means atactic polypropylene. The
data shows that the poly(ethylene-co-syndiotactic propylene)
samples have M.sub.e of about 1,000 compared to about 1,700 for PEP
counterparts showing that the poly(ethylene-co-syndiotactic
propylene) samples can tolerate more filler than PEP. This
characteristic is retained after crosslinking to provide
elastomer.
WORKING EXAMPLE I
Synthesis of Vinyl Containing Poly(ethylene-co-syndiotactic
propylene)
[0041] A 6 oz. Lab-Crest.RTM. glass pressure reaction vessel
(Andrews Glass) is charged with PMAO (0.30 g, [Al]/[Ti]=250) and
toluene (50 mL). The reactor is placed in an ice-bath. The nitrogen
atmosphere in the reactor is exchanged with propylene three times.
Propylene is condensed into the reactor for 30 min at 30 psi. The
ethylene is attached at 31 psi. 1,5-Hexadiene (1.0 ml) is added to
the reactor via syringe. The catalyst solution (19 mg of Catalyst G
described in U.S. Pat. No. 6,562,93, in 5 mL toluene) is injected
by syringe. After 90 min, acidic methanol (1 mL) is added by
syringe to quench the polymerization. The reactor is vented and the
polymer precipitated in acidic methanol (400 mL). After stirring
for several hours, the polymer is filtered, washed with methanol
and dried.
[0042] The functionalized product is admixed with 0.1 to 5 weight
percent sulfur and 5 to 50 weight percent carbon black filler and
the admixture is formed into a torus shape and crosslinking is
carried out by heating at 100 to 300.degree. C. for 10 minutes to 5
hours, to produce filled elastomer torus shape.
WORKING EXAMPLE II
Synthesis of Anhydride Containing Poly(ethylene-co-syndiotactic
propylene)
[0043] A 6 oz. Lab-Crest.RTM. glass pressure reaction vessel
(Andrews Glass) is charged with PMAO (0.30 g, [Al]/[Ti]=250) and
toluene (50 mL). The reactor is placed in an ice-bath. The nitrogen
atmosphere in the reactor is exchanged with propylene three times.
Propylene is condensed into the reactor for 30 min at 30 psi. The
ethylene is attached at 31 psi. The catalyst solution (19 mg of
Catalyst G described in U.S. Pat. No. 6,562,93, in 5 mL toluene) is
injected by syringe. After 90 min, acidic methanol (1 mL) is added
by syringe to quench the polymerization. The reactor is vented and
the polymer precipitated in acidic methanol (400 mL). After
stirring for several hours, the polymer is filtered, washed with
methanol and dried. The polymer is then mixed with maleic anhydride
and heated in the presence of the radical initiator benzoyl
peroxide to generate anhydride functional
poly(ethylene-co-syndio-propylene).
[0044] The functionalized product is admixed with 0.1 to 5 weight
percent hexamethylenediamine and 5 to 50 weight percent carbon
black filler and the admixture is formed into an ellipsoid shape
and crosslinking is carried out by heating at 100 to 300.degree. C.
for 10 minutes to 5 hours to provide filled elastomer
ellipsoid.
Variations
[0045] Variations will be obvious to those skilled in the art.
Therefore, the scope of the invention is defined by the claims.
* * * * *